Environmental Impact Assessment for the proposed Aluminium Pechiney smelter within the Coega Industrial Zone, Port Elizabeth, South Africa

Transcription

1 Environmental Impact Assessment for the proposed Aluminium Pechiney smelter within the Coega Industrial Zone, Port Elizabeth, South Africa SPECIALIST STUDY: MATERIALS HANDLING & SOLID WASTE September 2002 Prepared by Manufacturing and Materials Technology Sanjeev Raghubir, Auntony Mukhwanazi, Sibbele Hietkamp Manufacturing and Materials Technology, CSIR P O Box 395 Pretoria 0001 Prepared for CSIR Environmentek Stellenbosch CSIR Report reference: ENV-S-C (B)

2 SUMMARY Aluminium Pechiney intends to construct and operate an aluminium smelter using its latest AP50 reduction technology at a site located within the Coega Industrial Development Zone (IDZ) near Port Elizabeth. Associated infrastructure will also be constructed at the proposed Port of Ngqura. The CSIR has been commissioned by Aluminium Pechiney to conduct an Environmental Impact Assessment (EIA) for the proposed smelter. Various specialist studies have been identified for the EIA, and this document presents the Materials Handling and Waste Management specialist study report. Impact of Materials Handling Fugitive emissions and spillages from the handling of materials are expected to be small due to the best practice materials handling systems which will be employed by Aluminium Pechiney at the Port of Ngqura and at the smelter. Spillages are expected to be cleaned up promptly according to stringent housekeeping procedures. The environmental impact arising from materials handling is therefore not expected to be significant. Impact of Waste Generation The smelter will generate approximately tons of mixed solid waste per year which is approximately 57kg per ton aluminium produced. This is within the World Bank guideline of 40-60kg mixed solid waste per ton aluminium produced. Approximately t/a will be disposed of at landfill sites, while the rest will be re-used or recycled. Therefore only 21.5 kg mixed solid waste per ton aluminium will be landfilled. There exists opportunities to re-use or recycle more waste streams thereby further reducing the waste going to landfill, but this needs further evaluation. The Aluminium Pechiney smelter will adopt a waste management strategy (WMS) that supports and is consistent with the Nelson Mandela Metro Integrated Waste Management plan (IWMP). The environmental impact arising from waste generation is expected to have a low-medium significance due to the requirements for waste landfilling. Spent potlining (SPL) contributes a significant proportion to the total waste generated (25%), however, opportunities for reuse exist. SPLs will be stored in a temporary storage facility at the smelter site before being sent for processing. Potential SPL processing options include use in local cement or lime kilns, using the AUSMELT process or use in the Italian steel industry. However, it is recommended that a local solution is sought as this will prevent the long distance transportation and transboundary movement of hazardous waste. Contractual arrangements for the processing of the SPL need to be finalised before large volumes of SPL are generated (within 5 years of the smelter start-up). Aluminium Pechiney s activities (e.g. construction, port infrastructure operations, smelter operations, etc.) are expected to be executed according to an internationally recognised environmental management system (EMS) such as ISO The use of a wet scrubber for sulphur dioxide (SO 2 ) removal from the flue gases is not recommended, as this is not part of the best practicable environmental option (BPEO) internationally. Wet scrubbing leads to the generation of slurry waste requiring disposal and increased energy consumption. If required, reductions in SO 2 emissions can instead be achieved by using raw materials (e.g. HFO) with low sulphur content or replacing HFO with gas. However this depen ds on the availability of low sulphur HFO in South Africa and the availability of gas in the PE region. The anticipated regulatory permits needed by Aluminium Pechiney from a material handling and waste management perspective are: Aluminium Pechiney Coega EIA i

3 A waste disposal permit from the Department of Water Affairs and Forestry (DWAF) for the storage of SPL for more than 3 months A Major Hazard Installation permit from the PE local authorities A Basel Convention permit from the national Department of Environmental Affairs and Tourism for transboundary movement of hazardous SPL waste (if the SPL is transported to Italy for processing). The performance indicators calculated for the proposed smelter compare well with international guidelines (e.g. World Bank and the International Aluminium Institute), and other aluminium smelters using the AP18 and AP30 technologies. Aluminium Pechiney need to ensure that such performance is attained during the smelter operation. Aluminium Pechiney Coega EIA ii

4 CONTENTS Summary...i Contents...i List of Tables...iii List of Figures...iv Definitions...v Abbreviations...viii Units Used...viii 1. INTRODUCTION BACKGROUND Approach Scope of the study EXCLUSIONS REGULATORY REQUIREMENTS AND GUIDELINES South African legislation Pechiney s environmental guidelines International guidelines pertaining to aluminium smelters PROCESS DESCRIPTION Technology review MATERIALS HANDLING Materials handling at the Port of Ngqura Materials handling at the smelter WASTE GENERATION Waste generation at the Ports of Ngqura and Port Elizabeth Waste generation at the smelter during construction Waste generation at the smelter during start-up Waste generation at the smelter during operation Waste generated at the smelter during up -set conditions Waste generated at the smelter during closure Spent pot lining (SPL) Mass balance review Waste management IMPACTS OF MATERIAL HANDLING Material handling at Port of Ngqura Material handling at the Aluminium Pechiney smelter IMPACTS OF SOLID WASTE GENERATION Waste generated at the smelter during construction...26 Aluminium Pechiney Coega EIA i

5 9.2 Waste generated at the smelter during operation Effluent Generation Gaseous emissions RECOMMENDED MITIGATION MEASURES Material handling at the Ports and smelter Waste management during construction Waste minimisation at the smelter Waste recycling and re-use at the smelter Waste storage at the smelter Waste disposal Waste Management Strategy Solid waste Liquid effluent Gaseous emissions Monitoring Environmental Management System (EMS) PERMITS REQUIRED CONCLUSIONS REFERENCES APPENDICES List of Appendices Appendix A: : Impact Assessment...38 Appendix B: Aluminium Pechiney Smelter Waste Characterisation...45 Appendix C: Waste Disposal Site Classification In Terms Of The South African Minimum Requirements For Waste Disposal...49 Appendix D: Fluoride Input s And Outputs At The Pechiney Aluminium Smelter...50 Appendix E: Sulphur Balance At Aluminium Pechiney Smelter...51 Appendix F: Minimum Requirements For Waste Handling, Storage And Transportation...52 Appendix G: Extract From The Issues Trail In The Final Scoping Report, July Appendix H: Performance Indicators For Aluminium Manufacturing...56 Aluminium Pechiney Coega EIA ii

6 List of Tables Table 1: Air Emissions And Liquid Effluent From Aluminium Smelting...7 Table 2: Performance Indicators For Modern Aluminium Smelters, Including Mixed Solids Generation And Electricity Consumption [5]...7 Table 3: Main Inputs And Products For The Proposed Aluminium Pechiney Smelter...8 Table 4: Comparison Of Pre-Bake Technology With Soderberg Technology...11 Table 5: Destination And Amounts Of Waste Generated At The Aluminium Pechiney Aluminium Smelter...16 Table 6: Aluminium Pechiney Smelter Effluent Characterisation [17]...17 Table 7: Predicted Emissions From The Proposed Aluminium Pechiney Smelter [5, 12, 27, 28, 29, 30]...18 Table 8: Monitoring Elements For Solid, Liquid And Gaseous Waste...32 Table 9: List Of Permits Required Relating To Material Handling And Waste Management...33 Table A1 Impact Assessment Of Materials Handling At The Port Of Ngqura And The Aluminium Pechiney Smelter Before Mitigation...40 Table A2 Impact Assessment Of Materials Handling At The Port Of Ngqura And The Aluminium Pechiney Smelter After Mitigation...41 Table A3 Impact Assessment For The Aluminium Pechiney Smelter General Solid Waste Disposal Before Mitigation...42 Table A4 Impact Assessment For The Aluminium Pechiney Smelter General Solid Waste Disposal After Mitigation...42 Table A5 Impact Assessment For The Aluminium Pechiney Smelter Hazardous Waste Disposal Before Mitigation...43 Table A6 Impact Assessment For The Aluminium Pechiney Smelter Hazardous Solid Waste Disposal After Mitigation...43 Table A7 Impact Assessment For The Aluminium Pechiney Smelter Spl Storage And Processing...44 Table B1: Destination Of Solid Waste Generated...45 Table B2: Carbon Department...46 Table B3: Electrolysis Department...47 Table B4: Casthouse 47 Table B5: Laboratory And Environmental Operations...47 Table B6: Maintenance...48 Table B7: General Plant Operations...48 Table B8: Medical Centre...48 Aluminium Pechiney Coega EIA iii

7 Table C1: Classification System For Waste Disposal Sites...49 Table C2: Landfill Size Classes...49 Table D1: Fluoride Inputs And Outputs At The Aluminium Pechiney Smelter...50 Table E1: Sulphur Mass Balance...51 Table F1: Minimum Requirements For Waste Handling, Storage And Transportation...52 Table H1: Performance Indicators For Aluminium Manufacturing [5, 27, 28, 29, 30]...56 List of Figures Figure 1: Schematic of the Aluminium Production Process [7]...9 This report is to be cited as follows: Raghubir S, Mukhwanazi A and Hietkamp S Specialist study: Materials Handling and Solid Waste. In: Environmental Impact Assessment for the proposed Aluminium Pechiney Smelter within the Coega Industrial Zone, Port Elizabeth, South Africa. Specialist Studies Report, CSIR Report No. ENV-S-C (B), Stellenbosch, South Africa. Aluminium Pechiney Coega EIA iv

8 Definitions Alternatives A possible course of action, in place of another, that would meet the same purpose and need (of proposal). Alternatives can refer to any of the following but are note limited hereto: alternative sites for development, alternative site layouts, alternative designs, alternative processes and materials. In Integrated Environmental Management the so-called no go alternative refers to the option of not allowing the development and may also require investigation in certain circumstances. Alumina Alumina is the name given to the raw material, aluminium oxide (Al2O3), which is used in the smelting process to produce aluminium. It is a white powdery oxide produced through refining of bauxite. Aluminium Aluminium (in metallic form) is a relatively lightweight metal which is highly corrosion resistant, an excellent thermal conductor, non-magnetic, non-toxic and highly workable. End uses of aluminium include building and construction materials, electrical products, packaging and containers, cooking utensils, the aeronautical, automotive industries and leisure goods industries. Aluminium is produced by a smelting process which separates the aluminium from alumina (aluminium oxide) through electrolytic reduction. Anchor tenant Anchor tenants acts as catalysts for further investment (including improvements in local infrastructure and services) and as a magnet for other economic activities. They usually involve large-scale projects and in the construction and operational phases, present major employment and other economic opportunities for local enterprises Anode An anode is the name given to a positive electrode in a reduction cell. The anode used in the aluminium industry provides the positive electrical contact. The anode block is consumed during the smelting process. Assessment The process of collecting, organising, analysing, interpreting and communicating data that is relevant to some decision. Baking furnace The anodes produced at the paste plant are baked at about 1100 C in an oilfired furnace for several weeks in order to give them mechanical and conductivity properties. Bath This is the name given to the electrolytic medium within the pot through which the electric current is passed in the aluminium smelting process. Bath is made up of cryolite, alumina and aluminium fluoride. Bauxite Aluminium ore which is refined to produce alumina. Butt crushing plant Casthouse Cathode Cementation Cryolite At the butt crushing plant the spent anodes which are recovered from the potline are crushed in order for them to be used for the production of new anodes. Liquid aluminium which is extracted from the potline is transported to the casthouse where it is cast into aluminium ingots. A cathode is the name given to the negative electrode in a reduction cell. The cathode used in the aluminium industry provides the negative electrical contact as well as serving as the lining of the pot in which the smelting process takes place. Cementation is the process in which chemical precipitates (in the form of new crystals) form in the pores of a sediment or rock, binding the grains together. A mineral (sodium aluminium fluoride) which the main component of bath in the aluminium smelting process. Aluminium Pechiney Coega EIA v

9 Dross Dry scrubbing Electrolysis Environment Environmental impact Environmental impact assessment The skimmings on the surface of the molten aluminium which are removed because they contain impurities which could affect the quality of the aluminium metal produced in the smelter. The process whereby potential gaseous pollutants such as fluoride are attracted onto a solid substance and thereby removed from the air. An alternative approach is wet scrubbing but this has the disadvantage of producing additional liquid waste and may lead to corrosion. When electricity is passed through a liquid solution of an ion or an electrolyte, a chemical reaction called electrolysis occurs. The energy from the electric current breaks chemical bonds. In the aluminium smelting process this enables the separation of aluminium from alumina (aluminium oxide). The biophysical, social, economic, cultural, political and historical context within which people live and within which development takes place. A change resulting from the effect of an activity on the environment, whether desirable or undesirable. Impacts may be the direct consequence of an organisation s activities or may be indirectly caused by them. An Environmental Impact Assessment (EIA) refers to the process of identifying, predicting and assessing the poten tial positive and negative social, economic and biophysical impacts of any proposed project, plan, programme or policy which requires authorisation of permission by law and which may significantly affect the environment. The EIA includes an evaluation of alternatives, as well as recommendations for appropriate mitigation measures for minimising or avoiding negative impacts, measures for enhancing the positive aspects of the proposal, and environmental management and monitoring measures. Environmental A concern felt by one or more parties about some existing, potential or issu e perceived environmental impact. Fugitive emissions Emissions not caught by a capture system which are often due to equipment leaks, evaporative processes, and windblown disturbances. Fume treatment The fume treatment centre (FTC) extracts and recycles fluoride, polyaromatic hydrocarbon containing tar and dust from emissions created by the centre anode baking process. Gas treatment The gas treatment centres have the primary role of recycling the fluoride and centre dust captured from the pots. Hazardous Waste Waste that may, by circumstances of use, quantity, concentration or inherent physical, chemical or infectious characteristics, cause ill-health or increase mortality in humans, fauna and flora, or adversely affect the environment when improperly treated, stored, transported or disposed of. Industrial Development Zone Industrial waste Ingot Integrated environmental management An Industrial Development Zone is an area identified for industrial development. The aim is to attract domesti c and foreign investment into industrial and commercial parks by providing serviced industrial sites with purpose-built infrastructure. The solid, liquid, gaseous waste or any combination thereof generated by industrial processes and manufacturing Bars of aluminium metal which are produced as the final product of the primary aluminium smelting process. IEM provides an integrated approach for environmental assessment, management, and decision-making and to promote sustainable development and the equitable use of resources. Principles underlying IEM provide for a democratic, participatory, holistic, sustainable, equitable and accountable approach. Aluminium Pechiney Coega EIA vi

10 Interested and affected parties Key issue Liquid pitch Listed activities Individuals or groups concerned with or affected by an activity and its consequences. These include the authorities, local communities, investors, work force, consumers, environmental interest groups and the general public. An issue raised during the Scoping process that has not received an adequate response and which requires further investigation before it can be resolved. Pitch is a heavy, sticky, tar-like by-product derived from the coking of coal. It is used as a binding agent for the petroleum coke in the anode blocks, prior to baking. Development actions that are likely to result in significant environmental impacts as identified by the Minister of Environmental Affairs and Tourism in terms of Section 21 of the Environment Conservation Act. Megawatt A measure of power, equal to kilowatts or 1 million Watts. This is the unit used to quantify the electricity required by a given system. Mixed solid waste Solid waste that is not sorted into categories of materials Negative impact A change that reduces the quality of the environment (for example, by reducing species diversity and the reproductive capacity of the ecosystem, by damaging health, or by causing nuisance). Paste plant At the paste plant crushed petroleum coke and spent anode butts (the remainder of the anode which was not consumed in the potline) are mixed with liquid pitch to form an anode paste which is compacted into anode blocks prior to baking. Petroleum coke Petroleum coke is the main carbon source for the anode blocks. It is imported from overseas and is made from oil derivatives, which are regarded as a by-product by oil refineries. Pitch fume The pitch fume treatment centre (PFTC) treats PAH containing tar and dust treatment centre emissions from the paste plant. A change which improves the quality of life of affected people or the quality of Positive impact the environment. Pot The pot is the steel shell within which the aluminium smelting process takes place. Otherwise referred to as electrolytic reduction cells. Potline Pots are electrically connected and arranged in long buildings called potrooms. Two potrooms constitute a potline. Potlinings Potlinings consist of the refractory bricks that are used to insulate the steel shell of the pot (to contain the heat and prevent damage to the steel shell) and the carbon blocks that form the cathode. Reduction Reduction is an electrochemical process that involves the transfer of electrons from one atom to another. Reduction forms part of the electrolysis process. Relevant authority The environmental authority on national, provincial or local level entrusted in terms of the Constitution and in terms of the designation of powers in Notice No. R of 5 September 1997 with the responsibility for granting approval to a proposal or allocating resources. Rodding shop Newly manufactured anodes are attached to an electrical conducting stem in the rodding shop before being transported to the potline. Scoping This refers to the process of determining the spatial and temporal boundaries (the extent) for the EIA and key issues to be addressed in an environmental assessment. Smelting Aluminium smelting refers to the separation of aluminium from aluminium oxide. Spent Potlinings The potlinings which have reached the end of their useful life and which need to be replaced and disposed of. Aluminium Pechiney Coega EIA vii

11 Waste An undesirable or superfluous by-product, emission, or residue of any process or activity which has been discarded, accumulated or stored for the purpose of discarding or processing. It may be gaseous, liquid or solid or any combination thereof and may originate from a residential, commercial or industrial area. This definition includes industrial waste water, sewage, radioactive substances, mining, metallurgical and power generation waste. Abbreviations A 2 O 3 AP CO 2 CDC CSIR DEAT DEAE&T DSR EIA EIR FTC GTC I&AP IEM IDZ KV MW NMMM PAH PFTC PPP POP ROD SEA SMME SO 2 SPL Alumina (Aluminium Oxide) Aluminium Pechiney Carbon dioxide Coega Development Corporation Council for Scientific and Industrial Research Department of Environmental Affairs and Tourism (National) Department of Economic Affairs Environment & Tourism (Eastern Cape) Draft Scoping Report Environmental Impact Assessment Environmental Impact Report Fume Treatment Centre Gas Treatment Centre Interested and Affected Party Integrated Environmental Management Industrial Development Zone Kilovolt Megawatt Nelson Mandela Metropolitan Municipality Poly-aromatic hydrocarbon Pitch Fume Treatment Centre Public Participation Programme Persistent Organic Pollutants Record of Decision Strategic Environmental Assessment Small, Medium and Micro Enterprises Sulphur dioxide Spent potlining Units Used KG/ T AL MWH/T AL Kilogram per tonne of aluminium produced Megawatt hours per tonne of aluminium produced Aluminium Pechiney Coega EIA viii

12 1. INTRODUCTION Aluminium Pechiney intends to construct and operate an aluminium smelter using its latest AP50 reduction technology at a site located within the Coega Industrial Development Zone (IDZ) near Port Elizabeth (PE). The CSIR has been commissioned by Aluminium Pechiney to conduct an Environmental Impact Assessment (EIA) for the proposed smelter. The EIA is required to meet the South African legislative requirements, as well as ensure that all necessary environmental permit applications are prepared and submitted. Various specialist studies have been identified for the EIA, and this document presents the Materials handling and solid waste specialist study report. 2. BACKGROUND The proposed Aluminium Pechiney smelter will employ the latest AP50 reduction technology, which means that the proposed smelter will have one potline with 336 AP50 cells. The smelter will have the capacity to produce approximately tons of aluminium per year. A more detailed process description is provided in Section 5. The following major components are included in this Aluminium Pechiney project: [1]: 1 Electrolysis Potline with 336 AP50 cells in 2 potrooms 2 Gas Treatment Centres 1 Carbon Plant to produce the anodes including 1 Paste Plant and 2 Anode Baking Furnaces 1 Fume Treatment Centre for the Anode Baking Furnaces 1 Anode Rodding Shop including Bath Recycling Plant 1 Casthouse designed to solidify the liquid aluminium produced by the potline Silos for raw material storage and associated bulk material handling facilities on site Spent potlining (SPL) temporary storage facility Associated support facilities (i.e. maintenance workshop, laboratory, administration building, employee amenities). The project will also include the associated port infrastructures (e.g. off-loading facilities, liquid pitch storage facility, aluminium ingot storage area) that will be constructed at the proposed Port of Ngqura. A closed conveyer belt will also be constructed to transfer raw material (alumina and petroleum coke) from the Port of Ngqura to the Aluminium Pechiney smelter site. The construction and commissioning of the plant is planned to begin in 2003, and it is envisaged that the plant will be operating at full capacity by the end of Aluminium Pechiney Coega EIA 1

13 2.1 Approach The approach adopted for this specialist study was to acquaint the specialists with the proposed aluminium manufacturing process through [2]: Attendance of the briefing meeting in Stellenbosch. During the briefing meeting, Aluminium Pechiney representatives presented the aluminium smelting process, the new AP50 technology, and answered related questions. A review of relevant information on the aluminium manufacturing process, particularly the materials handling and waste management components. This included the following types of information: Process documentation sourced from Aluminium Pechiney World Bank Pollution Prevention and Abatement Handbook on aluminium smelting [5] Previous CSIR studies conducted for the aluminium industry, 2001 Discussions with CSIR in-house metallurgical and environmental specialists on the aluminium smelting process and related materials handling and waste management issues. Discussions with regulators with respect to permits needed and the permit application process. Presentation of interim results to Aluminium Pechiney at CSIR in Pretoria The various types of information collected and processed were thereafter used to determine the potential environmental impacts relating to materials handling and waste management. These impacts are described and mitigating measures are presented. During the study relevant information and results was made available to the other specialist study teams. The Materials handling and solid waste specialist study was integrated with other studies such as the Traffic and transportation specialist study (Lamprecht & Jones, 2002), Water use and liquid waste study (De Souza & Mackintosh, 2002), and Air quality specialist studies (Zunckel et al, 2002). This was done through discussions with other specialists and cross-referencing in the final specialist study reports. 2.2 Scope of the study This study considers the environmental impacts associated with the handling of raw materials and products onto and off the site, as well as the waste products generated through the aluminium smelting and associated process [2]. In particular, the study: Provides a detailed examination of the chemical process used to smelt aluminium in terms of the potential risk to the environment under normal conditions, start-up and shut-down, maintenance operations, and upset plant conditions. Provides a comprehensive mass-balance to ensure that all waste streams have been identified and characterised in terms of quantities generated, composition and disposal options. Provides a clear summary of the amount of waste (solid, liquid or gas) produced for each ton of aluminium. If possible, compare this with international averages Aluminium Pechiney Coega EIA 2

14 (e.g. from the World Bank Pollution Prevention and Abatement Handbook) and results from the aluminium industry. Reviews the technology to be used (e.g. unit operations) in terms of the best practicable environmental option principle. Evaluates the environmental risks associated with the movement of materials associated with the manufacturing process, including inter alia: Transport of raw materials from the PE harbour to the site. Transport of raw materials from the proposed Port of Ngqura to the site. The handling of materials at the ports and at the smelter site. Evaluates the environmental risks associated with the storage of materials on-site. Provides a detailed account of waste management opportunities and threats with particular emphasis on any hazardous waste that are identified. This provides an overview of waste management within the Nelson Mandela Metropolitan Municipality and includes an evaluation of the various waste management options which may be available, in order to identify the best practicable environmental option. Provides a detailed review of national legislative requirements pertaining mainly to waste and effluents of the proposed smelter (e.g. Minimum Requirements for Waste Disposal as referred to in the Environmental Conservation Act (Act 73 of 1989), Major Hazardous Installations regulations of the Occupational Health and Safety Act (Act 85 of 1993), National Water Act (Act 36 of 1998), etc.) The specialist study identifies all permits required for waste management and materials handling on and off the Aluminium Pechiney site. Subsequently, the necessary permit application will be prepared, working together with the EIA Project Manager, Aluminium Pechiney and the relevant authority. Identifies international conventions and protocols to which South Africa is signatory and which are of relevance to this study and to the proposed development. Identifies and discuss any remedial and mitigation measures that could be employed to reduce any of the impacts identified through the above studies. This includes an evaluation of the potential for recycling and reuse of materials both by other industries and by small medium and micro enterprises (SMMEs). As far as possible, mitigation measures for minimising waste and for reducing the risk of spillages include process and technology related measures, as well as good practice guidelines for employees and for equipment maintenance. Provides and discusses potential monitoring and measuring plans that would be needed by Aluminium Pechiney to assist in managing the environmental impacts identified in the specialist study. Provides and discusses sustainability indicators for the Aluminium Pechiney smelter. This includes indicators such as solid waste produced per ton of aluminium. These sustainability indicators are compared to similar local and international operations where information was available. The specialist study also takes into account the following: Impacts are described according to the convention presented in Appendix A. Impacts are described both before and after the proposed mitigation and management measures have been implemented. All impacts are evaluated for the full-lifecycle of the proposed development, including construction, operation, decommissioning and closure. The impact Aluminium Pechiney Coega EIA 3

15 evaluation also takes into consideration the cumulative effects associated with this and other facilities that are either developed or in the process of being developed in the region. The specialist study is subject to review by an independent party. 3. EXCLUSIONS This specialist study presents the solid waste generation, handling and disposal and liquid effluent and gaseous emissions from the proposed Aluminium Pechiney smelter, however only the impacts resulting from the solid waste management will be addressed. The impacts resulting from liquid effluent and gaseous emissions are addressed in the respective specialist studies. No solid waste was sampled and analysed during this specialist study. The quantities and compositions of waste materials were obtained from Aluminium Pechiney and other sources. 4. REGULATORY REQUIREMENTS AND GUIDELINES 4.1 South African legislation There are various Acts and regulations that regulate environmental management in South Africa, as well as different by-laws that regulate industrial activity. The following are the key Acts against which this specialist study is evaluated: The National Environmental Management Act (NEMA), (Act 107 of 1998) This Act forms the overarching framework for environmental management in South Africa and incorporates, amongst others, the principles embodied in the White Paper on Integrated Pollution and Waste Management for South Africa (Jan. 2000), and the National Waste Management Strategy documents (Oct. 1999). The key principles include moving away from the end- of- pipe treatment approach towards the prevention of pollution and waste and avoiding environmental degradation. The Environmental Conservation Act, (Act 73 of 1989) Sections 21, 22 and 26 of this Act were promulgated in 1997, and make Environmental Impact Assessments a statutory requirement for specified new developments. Section 20 of this Act indicates that waste can only be disposed of at a waste disposal facility that has a permit issued by the Minister of Water Affairs and Forestry. Such a waste disposal facility must be in accordance with the Department s Waste Management Series, Minimum Requirements documents [3]. Regulations in terms of Section stipulate the requirement for a permit from DWAF for temporary onsite storage of hazardous waste. This permit would be required for the temporary storage of SPLs on the Aluminium Pechiney smelter site. The National Water Act, (Act 36 of 1998) This Act includes strict measures to protect water resources. The Act provides for the protection of groundwater resources and has implications for waste storage, disposal and effluent discharge. Implications of the NWA for the Aluminium Aluminium Pechiney Coega EIA 4

16 Pechiney project will be addressed in the Water Use and Liquid Waste Management specialist study. The Air Pollution Prevention Act, (Act 45 of 1965) This Act is concerned with emissions at stacks and specifies acceptable levels of pollutants in the air. Scheduled processes are identified in the Act and the allowable emissions and ambient air quality guidelines are provided. The Occupational Health and Safety Act, (Act 85 of 1993) The following regulations are based on this Act and are particularly relevant to the chemical industry: Hazardous Chemical Substances Regulations (R1179, 25 Aug. 1995), which identify hazardous chemicals, and how they should be controlled so as to ensure safe working conditions for employees. Major Hazard Installation Regulations (R6077, 16 Jan. 1998), which sets out the responsibilities for the control of facilities that have, either permanently or temporarily, an installation or a quantity of a substance which can pose a significant risk of resulting in a major incident that could affect the health and safety of persons outside the premises, including the public. A risk assessment is required in order to determine whether or not the Aluminium Pechiney smelter site and the storage facilities at the Port of Ngqura are to be classified as Major Hazardous Installations. This risk assessment has been initiated by Aluminium Pechiney and results will be incorporated into the EIA process. South African legislation on waste management is still undergoing change. While the Government s key waste management objectives, i.e. moving away from fragmented and uncoordinated waste management to integrated waste management in order to reduce both the generation and the environmental impact of waste), are included in the legislation such as the National Environmental Management Act (Act 107 of 1998) and Environmental Conservation Act (Act 73 of 1988), the following are currently being written: A Draft Bill on Waste Management is being drawn up by the Department of Environmental Affairs and Tourism (DEAT): it includes among many other provisions substantial fines (as high as R5 million) for pollution offences. Potential new developments within the Bill include the use of Best Available Technology Not Entailing Excessive Cost (BATNEEC) instead of Best Practicable Environmental Option (BPEO); a requirement for Industry Waste Management Plans; a requirement for the company to have an Environmental Compliance Certificate and requirements for Import/Export of wastes via the Basel Convention. A new National Air Quality Management Bill is being developed by DEAT as part of the South African air law reform process. This act will replace the current Air Pollution Prevention Act, and it may impose emission standards similar to those currently prevailing in the European Union (EU). Revisions of the current Minimum Requirements Series of documents plus a new document that will cover auditing of waste facilities, staff minimum qualifications and training requirements. Aluminium Pechiney Coega EIA 5

17 4.2 Pechiney s environmental guidelines Pechiney have their own environmental policy [4] wherein it states that environmental protection, health and safety are key priorities in the company s strategy and the Pechiney Continuous Improvement System (Box 1). Box 1: Pechiney is committed to applying and implementing the following guidelines throughout the Group: 1. To ensure transparency in issues concerning environmental protection, health and safety, in particular by evaluating and publishing achievements and performances measured by selected indicators applicable to the Group s activities; 2. To ensure regulatory compliance of operations and facilities, as well as compliance with the internal standards the Group is developing to align its practices. 3. To ensure continuous improvement of employees health and safety conditions and those of Group subcontractors; 4. To continue to reduce the environmental impact of the Group s past, current and future activities as well as of its products, by limiting emissions and waste, optimising processes, managing the risk of accidents, remediation of any damage done, and developing partnerships with customers and suppliers. 5. To develop products that are more considerate of the environment by analysing their life cycles, from design to recycling. 6. To implement the best available and most economically viable technology in new investments and the best environmental practices throughout the Group. 7. To manage industrial risks through efficient identification and ranking procedures, as well as by the implementation of appropriate prevention and protection measures and their ongoing adaptation. 8. To organize a scientific health watch activity to detect and control new risks. To honour these commitments, Pechiney works with all concerned parties. The group promotes employee involvement at all levels and is introducing a risk management system for environmental protection, health and safety at is facilities. This system makes it possible to organise progress planning, achievement and continuous improvement, define each employee s responsibilities, train the workforce and inform suppliers of the requirements of the Group s business units. The Company also measures progress on a regular basis, conducts periodic audits to detect and correct deviations, and facilitates sharing best practices. Source: Pechiney (2001) 4.3 International guidelines pertaining to aluminium smelters According to the World Bank published Pollution Prevention and Abatement Handbook for aluminium manufacturing [5], air emission and effluent guidelines are specified as presented in Table 1. Aluminium Pechiney Coega EIA 6

18 Table 1: Air emissions and liquid effluent from aluminium smelting PARAMETER Air emissions Liquid effluent * MAXIMUM VALUE (mg/nm 3 ) PARAMETER MAXIMUM VALUE (mg/l) (ex cept ph and temperature) Particulate matter 30 ph 6 9 Hydrogen fluoride 1 TSS 50 Total fluoride 2 Fluoride 20 Volatile Organic Compounds (VOCs) 20 Aluminium 0.2 COD 150 Hydrocarbons 5 Temperature =3 C higher than increase receiving body* * The effluent should result in an increase no more than 3 C at the edge of the zone where initial mixing and dilution take place. Where no zone is defined, use 100 meters from the point of discharge. It is further stated in the Handbook that modern smelters, using good industrial practices, are able to achieve the performance indicators as presented in Table 2 (all values are expressed on an annualised basis). Typical solid waste generation and electricity consumption figures are also presented in Table 2. Table 2: Performance indicators for modern aluminium smelters, including mixed solids generation and electricity consumption [5] PARAMETER POLLUTANT LOAD Total particulates 1 (kg/t Al) Hydrogen fluoride Total fluoride Sulphur dioxide 1 1 Nitrogen oxides 0.5 CF4 0.1 Mixed solid waste Electricity (Pre-bake technology) kg/t Al 14 MWh/t Al 5. PROCESS DESCRIPTION The main raw materials and other inputs that are used in the aluminium smelting process are presented in Table 3. The values and Notes provided are specific for the proposed Aluminium Pechiney plant at Coega [6]. The final product (aluminium ingots) from the 1 The SO2 emissions are given for aluminium smelters using dry and wet scrubbing abatement technologies. However, the World Bank also does not require the installation of wet scrubbing pro cesses as they result in significant increases in slurry wastes (Section ). Aluminium Pechiney Coega EIA 7

19 proposed smelter is also presented in the table, and the Notes outline the modes of transport of the raw materials and products to and from the proposed Aluminium Pechiney site. Table 3: Main inputs and products for the proposed Aluminium Pechiney smelter RAW MATERIALS, OTHER INPUTS and PRODUCT Alumina Calcined coke Liquid pitch Petroleum Aluminium fluoride (AlF 3 ) Heavy fuel oil (HFO) AMOUNT (per year) t t t t t NOTES Imported to Port of Ngqura in dedicated ships as solid bulk fine material. Vacuum/suction unloaded at the Port then transported to sealed holding silos at Aluminium Pechiney by closed belt conveyer. Imported to Port of Ngqura in dedicated ships as solid bulk. Vacuum/suction unloaded at the Port then transported to a coke storage shed at Aluminium Pechiney by closed belt conveyer. Imported to Port of Ngqura as hot liquid bulk, and off loaded using a liquid pitch off-loading facility. Stored at the Port in a specialised storage vessel and transported to the Aluminium Pechiney site by road tanker. Imported to PE or Port of Ngqura as break bulk (1 ton bulker bags or 25kg layer bags). Off loaded using General Cargo facilities and then transported to Aluminium Pechiney by truck for storage and use. Stored at the PE Port in existing storage vessels. Transported to Aluminium Pechiney by tanker-truck. 3 Water supplied by Nelson Mandela Metropole Municipality Water m from the Nooigedacht water treatment works. Electricity Aluminium (final product) ingots 860 MW From Eskom by means of dedicated powerlines t Aluminium ingots transported to the harbour by specialised trucks, and exported by ship. A schematic of the aluminium production process as will be employed by Aluminium Pechiney is presented as Figure 1 [7]. The schematic shows the various flows of materials associated with the aluminium production process. Aluminium Pechiney Coega EIA 8

20 Figure 1: Schematic of the aluminium production process [7] The 3 major process components of the proposed Aluminium Pechiney smelter are [7]: the electrolysis Potline with 336 AP50 cells in 2 halls, a Carbon Plant and Anode Rodding Shop for anode production, and a Casthouse to solidify the liquid aluminium produced by the Potline into ingots. The Potline The smelting process uses electrical energy and carbon to break the bonds between aluminium (Al) and oxygen (O 2 ) in the alumina (Al 2 O 3 ) in order to produce liquid aluminium. 2Al2O3 + 3C? 4Al + 3CO2 This process occurs in large steel containers called reduction pots, which are arranged in long buildings called potrooms. Two potrooms constitute a potline. The potline proposed for the Coega IDZ would consist of 2 elongated potrooms measuring 1200m x 30m. Each room would house a line of 168 pots in two groups of 84 pots, electrically connected. There would be 336 pots in total in the potline. Each pot represents one large electrolytic cell. They are lined with carbon blocks and refractory bricks to insulate the pots and contain the heat. This potlining also forms the positive contact (the cathode) for the electric current which is passed through a molten bath of sodium aluminium fluoride (cryolite), alumina and aluminium fluoride in the pots. Carbon anodes (made of petroleum coke and pitch) are used to conduct electricity into the pots. The anode block is consumed during the smelting process. The heat generated by passing the electric current through the cell maintains the bath in liquid form at about 950 C. Aluminium Pechiney Coega EIA 9

21 A steel-reinforced structure supports the overall pot including the anodes, cathode shell, a hooding system and the alumina supply hopper. The supply hopper automatically feeds fluoride-enriched alumina from the Gas Treatment Centre (GTC) into the pots where it is dissolved in the molten cryolite. Liquid aluminium is tapped periodically from the pots by vacuum suction and transferred to the Casthouse and holding furnaces in refractory lined steel crucibles. Associated with the potline are two Gas Treatment Centres (GTC's) positioned between the potrooms to receive emissions from the pots. In addition to carbon dioxide (CO2), emissions consist primarily of fluoride, sulphur dioxide and dust. The GTC s are dry scrubbing units, having the primary role of recycling almost all the fluoride and dust captured from the pots. The dry scrubbing system is not efficient for SO2 abatement. Alumina is used as a scrubbing agent to extract the fluoride from the emissions. The fluorinated alumina is then directed into the pots. The Carbon Plant and Anode Rodding Shop The carbon anodes are gradually consumed during the smelting process. The expected life of an anode is approximately 640 to 770 hours, so they are replaced on a rotating schedule. Due to this high demand for anodes, they would be manufactured on site in a carbon plant by a 3-stage process: Paste plant - Green (unbaked) anodes would be produced by crushing petroleum coke and spent anode butts (the remainder of the anode which was not consumed in the Potline) then mixing it with liquid pitch to form an anode paste and compacting the paste into anode blocks. Baking furnace - The anodes are baked at about 1100 C in an oil-fired furnace for several weeks in order to give them mechanical and conductivity properties; Rodding shop - Anodes are then attached to electrical conducting rods in the rodding house and transported to the Potline. Associated with the anode-baking furnace is a fume treatment centre (FTC) to extract and recycle fluoride, poly-aromatic hydrocarbon (PAH) containing tar and dust from emissions created by the anode baking process. This is a dry scrubbing unit, also utilising raw alumina as the scrubbing agent with the resultant enriched alumina being recycled into the pots resulting in PAH destruction. There is also a pitch fume treatment centre (PFTC) associated with the paste plant. This is a dry scrubbing unit that treats PAH containing tar and dust emissions from the paste plant, using particulate coke as the scrubbing agent. This enriched coke is recycled into the paste plant. Aluminium Pechiney Coega EIA 10

22 5.1 Technology review The 1997/1998 Action Plans of the Oslo and Paris Conventions for the prevention of marine pollution calls for the adoption of best available techniques (BAT) and best environmental practice (BEP) to reduce or eliminate pollution sources from the aluminium sector. For aluminium smelting, BAT includes [9]: a. Closed pre-bake pots, designed for high collection efficiency for fumes and minimal opening of enclosures during operation; b. Point feeding of aluminium oxide, intermittently to the centre line of the cell; c. Efficient computer process control to control bath composition and limit anode effects; d. Pot exhaust gas cleaning by adsorption of fluorides on aluminium oxide, removal of particles and recycling of aluminium oxide to the pots; Careful and efficient operation and maintenance; Monitoring of emission of air pollutants, by frequent sampling or continuous measurements. For Anode producing, BAT includes [8]: a. Fume scrubbers installed at tanks for molten pitch, with the recovered tar from scrubbers recycled or used as fuel. b. Cooling of air exhaust containing tar fumes, followed by demister or fabric filter coated with petrol coke to separate tar. c. Residues and dust from anode butts cleaning to be recycled. d. Petroleum coke dust and tar recovered in air pollution control equipment to be recycled or used as fuel. e. Tar, petrol coke, Al2O3 and other wastes from the gas cleaning to be recycled or used as raw material and fuel. The World Bank Pollution Prevention and Abatement handbook for aluminium manufacturing [5] also lists a few key production and control practices that would lead to compliance with emission guidelines. This includes the preference for Pre-bake processes for aluminium smelting as opposed to the Soderberg technology. This is due to the associated reduced atmospheric emissions and energy efficiency of the pre -bake technology as shown in Table 4. According to the Oslo and Paris Conventions, Pre -bake technology is BAT for aluminium electrolysis. Table 4: Comparison of Pre-bake technology with Soderberg technology TECHNOLOGY GAS COLLECTION EFFICIENCY ENERGY CONSUMPTION (MWh/t Al) Pre-bake 98% 14 Soderberg 90% 17.5 Aluminium Pechiney Coega EIA 11

23 These BAT are inherently included in the Aluminium Pechiney process design, will be employed in the proposed smelter. Other BAT features that are inherent to the Aluminium Pechiney smelter design include: Process emission monitoring by on-line real-time analysers at the Potrooms and Dry Scrubbers Water emissions Increased undercover handling of process materials contributing to reduced stormwater contamination Reduced footprint of sealed and roofed areas contributing to reduced stormwater contamination Closed circuit water cooling systems for metal casting, anode production and compressed air systems Application of dry scrubbing emission control systems in place of wet scrubbers Solid waste Reduced rate of Spent Potlining generation per ton of aluminium produced through enhanced economies of scale Maximisation of Pot life leading to further reduction in SPL generation Maximisation of furnace refractory life leading to minimisation of refractory brick waste Total internal recycling of consumed anode butts Total internal recycling of Bath products Full recycling of fluoride emissions captured by Dry Scrubbing systems Material handling Application of BAT for raw materials unloading at Port - Vacuum Unloaders Direct feeding of alumina to pots through Hyper Dense Phase pneumatic system Enhanced integrated plant layout minimising transport distances of raw materials and intermediate products Application of fully enclosed pneumatic systems for internal transport of alumina and bath products Covered conveyor systems for materials handling - minimising wind losses, waste generation and groundwater / stormwater contamination risks All transfer points of conveyors and pneumatic systems served by dust filters to control dust and material losses Management systems Application of Corporate standard for ISO EMS Multi-year EHS Action Plans Corporate Continuous Improvement System integrating Environment, Health and Safety policies Corporate greenhouse reduction commitment under the Partnership for Climate Action programme Others Minimisation of smelter footprint requiring lower land surface area The Aluminium Pechiney smelter is based on the latest Pechiney prebake reduction technology (AP50 electrolytic pots) that uses the Hall-Heroult process to produce aluminium. The smelter is made up of 1 Electrolysis Potline with 336 AP50 cells. It is reported [4] that the AP50 electrolysis technology will make it possible to lower investment costs by approximately 15% compared with the AP30 technology. In addition to the BAT already employed, there are also potential environmental benefits of the new AP50 technology, such as reduced greenhouse gas emissions and solid waste generated. It is claimed by Aluminium Pechiney Coega EIA 12